Prodlacta

Founded in 1900 in Brașov, Prodlacta boasts a century-long tradition in milk processing that has taken it from a small local dairy to one of Romania’s leading dairy players, always focused on innovation and community well-being. In 2024, Prodlacta entrusted Zudek with a complete overhaul of its refrigeration system to raise safety standards and reduce energy costs. As an integral part of the local community, the dairy required a project capable of lowering the circulating ammonia quantity while simultaneously improving the overall performance of the system.

Originally, Prodlacta’s plant used 3,000 kg of ammonia to produce glycol at –10 °C. The glycol, used to cool large ice storage tanks, was highly inefficient, resulting in significant thermal losses, operational complexity, and very high electricity consumption. Both the refrigerant charge and the storage mechanism required a radical redesign.

The goals shared with Prodlacta were clear: drastically reduce the amount of ammonia to lower the risk of potential leaks and increase energy efficiency, while keeping operational costs down and ensuring a quick return on investment.

Zudek proposed a modular solution based exclusively on natural refrigerants:

• two air-cooled Airmatik units, each with a cooling capacity of 1,000 kW, equipped with a Zeromatik system for continuous production of chilled water at +1 °C
• complete elimination of the ice storage tanks
• an additional Airmatik unit for glycol production at –10 °C
• a dedicated pumping skid and control panels for primary and secondary circuits, featuring advanced automation logic

The results fully reflected the initial objectives: the ammonia charge dropped from 3,000 kg to just 400 kg, significantly reducing leak risks; overall system efficiency improved by 30%, resulting in substantial electricity savings that will allow Prodlacta to pay off the investment in less than three years. Additionally, the more compact footprint of the new units freed up space in production areas, offering greater logistical flexibility and expansion potential without requiring further construction work.

This intervention confirms how Zudek’s philosophy, based on the use of natural refrigerants and integrated design, makes it possible to combine environmental sustainability, operational safety, and economic efficiency. Today, Prodlacta benefits from a safer, more efficient system that’s ready to meet the future challenges of the dairy market.